However, they eventually decided to use a “mixed material” strategy.

The new 2020 Ford Explorer rides on an entirely new platform, which will be used by Ford for several upcoming models, such as the 2020 Lincoln Aviator. Ford’s three-row SUV weighs in at around 200 pounds (91 kg) less than its predecessor, and is up to 36% torsionally stiffer. However, this doesn’t mean that it uses all-aluminum architecture. Ford initially considered an all-aluminum body, but decided to use a “mixed material” strategy.

The automaker made this decision because an all-aluminum vehicle would have increased the final price for customers. A smart platform that is made from a mixture of steel, aluminum and magnesium has a stiffness almost equal to an all-aluminum model, especially when you consider the lighter and more robust products in today’s steel industry. The hybrid powertrain and efficient engines increase fuel economy without the need for an expensive all-aluminum structure.

The Detroit Free Press report outlines some of the smart solutions that the new Explorer has for reducing noise and vibration, as well as lowering weight and stiffness. For example, the panel that separates cabin and engine compartment is dimpled “like golf balls” to keep the interior quiet. To reduce the weight, the chassis was also made of small steel pieces. The cooling radiator is also held in place with magnesium and plastic as a weight-saving measure.